Apparatus for forming a prefabricated truss deck



Oct. 31, 1967 w. w. FRANTZ ,4 APPARATUS FOR FORMING A PHEFABRICATEDTRUSS DECK 7 Original Filed June 5, 1964 5 Sheets-Sheet l INVENTOR. .363 WUO fi/PUW h! EPA/VIZ 2 2 BY Z Q: 1 H111 J if! Armzwnm Oct; 31, 1967w. w. FRANTZ APPARATUS FOR FORMING A PREFABRICATED TRUSS DECK 5Sheets-Sheet 2 Original Filed June 5, 1964 gAzNJ/ Oct. 31, 1967 w. w.FRANTZ 3,349,457

APPARATUS FOR FORMING A PREFABRICATED TRUSS DECK 36 ,/7 .96 r A j ,g/70- K I U aa w U 48 IN VENTOR. 98 2 W00040W 14 F/PA/W'Z United StatesPatent Ofiiice 3,349,457 APPARATUS FOR FORMING A PREFABRICATED TRUSSDECK Woodrow Wilson Frantz, Nazareth, Pa., assignor to Conodec, Inc.,Easton, Pa., a corporation of Pennsylvania Original application June 5,1964, Ser. No. 372,796, now Patent No. 3,305,612, dated Feb. 21, 1967.Divided and this applicafion Sept. 27, 1966, Ser. No. 582,386

Claims. (Cl. 252) ABSTRACT OF THE DISCLOSURE Apparatus for forming aprefabricated truss deck having a flat stationary floor with pivotablymounted side walls, cut-off bars to divide the apparatus into aplurality of chambers and a dispensing hopper for dispensing acementitious mixture into the chambers.

This application is a divisional application of application Ser. No.372,796 filed June 5, 1964, now Patent 'No. 3,305,612.

This invention relates to an apparatus for producing a prefabricatedtruss deck.

Prefabrication of structural components for a building has becomewidespread. It has been found that structural components can be moreeconomically shop fabricated and assembled at the construction site.

This invention relates to the shop fabrication of a floor or r-oofcomponent. In particular, this invention deals with the fabrication of afloor or roof component comprising a pair of substantially parallel openweb steel joists embedded within a precast concrete slab.

Accordingly, it is an object of this invention to provide apparatus forforming a prefabricated truss deck.

A more specific object of this invention is to provide apparatus forforming a prefabricated truss deck in a more economical manner.

Yet another object of this invention is to provide apparatus for forminga plurality of prefabricated truss decks in a single continuousoperation.

Another object of this invention is to provide apparatus for forming aplurality of prefabricated truss decks in a single continuous operationwhich can easily be joined to each other at the construction site forforming a roof or floor.

Other objects will appear from the disclosure which follows hereinafter.

For the purpose of illustrating the invention, there is shown in thedrawings a form which is presently preferred; it being understood,however, that this invention is not limited to the precise arrangementsand instrumentalities shown.

FIGURE 1 is a top plan view of a portion of the apparatus used incarrying out the method of the instant invention and illustrates acasting bed and a hopper mounted thereon for selectively dispensing acementitious mixture into the casting bed.

FIGURE 2 is an end view in elevation of the apparatus illustrated inFIGURE 1 as seen substantially along the plane indicated by the line 2-2of FIGURE 1.

FIGURE 3 is a fragmentary cross sectional view taken substantially alongthe plane indicated by the line 3-3 of FIGURE 2.

FIGURE 4 is an end view in elevation of the structure illustrated inFIGURE 3 as seen from the plane indicated by the line 44 of FIGURE 3.

FIGURE 5 is a fragmentary perspective view of one end of the casting bedillustrated in FIGURE 1.

FIGURE 6 is a'perspective view of preassembled truss structurecomprising a portion of the end product formed by the method andapparatus of the instant invention.

FIGURE 7 is an enlarged fragmentary plan view of one end of the trussillustrated in FIGURE 6.

FIGURE 8 is a fragmentary cross sectional view taken substantially alongthe plane indicated by the line 8-8 of FIGURE 7 and also showing inphantom the manner in which the truss is adapted to be located relativeto the casting bed in accordance with the method of the instantinvention.

FIGURE 9 is a fragmentary enlarged plan view of the other end of thetruss illustrated in FIGURE 6.

FIGURE 10 is a fragmentary cross sectional view taken substantiallyalong the plane indicated by the line 1010 of FIGURE 9 and alsoillustrating in phantom the manner in which the truss is adapted to belocated with respect to the casting bed when carrying out the method ofthe instant invention.

FIGURE 11 is a top plan view similar to FIGURE 1 but showing the hoppercarriage moved along the casting bed and a first truss member disposedwithin the casting bed.

FIGURE 12 is a fragmentary cross sectional view taken substantiallyalong the plane indicated by the line 1212 of FIGURE 11.

FIGURE 13 is an enlarged detail of the lefthand portion of FIGURE 12indicated by the circle 13.

FIGURE 14 is a fragmentary cross sectional view taken substantiallyalong the plane indicated by the line 1414 of FIGURE 12 and showing inphantom the location of a second truss element on the casting bed withrespect to a first truss element.

FIGURE 15 is a top plan view as seen substantially along the planeindicated by the line 1515 of FIGURE 14 FIGURE 16 is an end view onelevation illustrating the manner in which a pair of identical trussdecks formed by the apparatus of the present invention can be joined toeach other in constructing a roof or floor.

FIGURE 17 is an enlarged detail view, partly in section, of the centralportion of FIGURE 16 indicated by the circle 17.

The apparatus of the instant invention includes a casting bed generallydesignated by the numeral 20.

The casting bed 20 includes a floor 21. The floor 21 is mounted on thetop flanges of a pair of parallel I-beams 40 and 44 running the lengthof the casting bed. Mounted between the opposed webs of the I-beams 40,44 adjacent their ends, are a pair of parallel, rectangular beams 41 and42. The I-beams 40 and 44 are supported by transverse beams 23 and 24 attheir respective ends.

A side wall 48 is pivotally connected to the web of the I-beams 40.Similarly, a side wall 50 is pivotally connected to an Lbeam 44. Sidewalls 48 and 50 extend the longitudinal length of the I-beams.

The side walls 48 and 50 include a plurality of longitudinal-ly spacedtriangularly shaped brackets 60. Secured to the webs of the I-beams 40and 44 are a plurality of pairs of triangularly shaped brackets 62. Eachof the brackets 60, 62 include a hinge collar 64. The hinge collar onthe bracket 60 is disposed between the hinge collars on a pair ofbrackets 62 and a hinge pin is inserted within the collars.

End walls 46 and 52 are supported at remote ends of the casting bed 20upon the top flanges of the I-beams j 40 and 44. The end walls 46 and 52are pivotally mounted to the rectangular beams 42 and 41 respectively. Aplurality of triangular brackets 54 terminating in a hinge collar 58 aresecured to the end walls 46 and 52. Pairs of spaced triangular brackets56 are secured to the rectangular beams 42 and 41. The brackets 56 alsoterminate in a hinge collar 58. The hinge collars on the brackets 54 aredisposed between a pair of adjacent hinge collars on the brackets 56 anda pivot pin is run through the aligned collars.

A pair of rails 26 and 28 are supported on the top of the transversebeams 23 and 24 and run the length of the casting bed 20. Mounted on therails 26 and 28 in overlying relation to the casting bed floor 21 is ahopper 22 for dispensing cementitious material. The hopper 22 includes aplurality of wheels 30 in engagement with the tracks 26 and 28.Connected to one of the wheel axles 32, as shown in FIGURE 2, is asprocket about about which is entrained an endless chain 38. A bracket34 extends in cantilever fashion from the side of the hopper 22. Anelectric motor 36 is supported upon the bracket 34. A sprocket ismounted upon the motor shaft and engages the endless chain 38.Therefore, upon act-uation of the electric motor 36, the wheels 30 ofthe hopper 22 will be rotated and the hopper can be caused toselectively move along the casting bed 20.

In the fabrication of the truss deck by the method of the instantinvention, a preassembled truss 66 is provided. The truss 66 includes apair of spaced, substantially parallel joist sections 68 and 70. Thejoist sections 68 and 70 are connected by a steel joist web 72. Theouter portions of the joist web 72 are inclined away from the bottomchord of the joists 68 and 70.

The top chord 74 of each joist section includes a pair of slopingextensions 76 and 82 at its opposite ends. The extensions 76 and 82terminate in horizontal portions 78 and 84 respectively. The horizontalportion 78 includes an aperture 80. Similarly, the horizontal extension84 includes an aperture 86.

Removably secured to the horizontal extension portion 78 is an angleiron positioning bar 88. Core pins 90 connect the positioning bar 88 tothe horizontal extension 78 by being inserted within the apertures 80.

A Z-shaped cut-off bar 92 is removably supported upon the horizontalextension 84. It will be noted that the cut-off bar 92 has a verticalportion which is generally perpendicular to the floor 21 as shown inFIG- URE and extends between the side walls 48 and 50 as shown moreclearly in FIGURE 15. The cut-off bar 92 also has a generally horizontalportion extending from the upper edge of the vertical portion so that itmay overlie an end portion of the material 96 as shown more clearly inFIGURE 14. Core pins 94 attached to the cut-off bar 92 are inserted inthe apertures 86 in the horizontal extensions 84.

As shown in FIGURES 12 and 13, a continuous upstanding flange 98 isprovided along the opposite longitudinal edges of the floor 21 of thecasting bed 20.

The method of the present invention is carried out with the previouslydescribed apparatus, substantially as follows:

The side and end walls of the casting are disposed in their upperpositions to close the casting bed. A light oil film is applied to theinside flanges of the side walls 48 and 50 and the end walls 46 and 52of the casting bed 20. The oil film is also applied on the floor 21 ofthe casting bed.

The motor 36 is actuated to cause movement of the hopper 22 along therails 26 and 28. As the hopper 22 moves along the casting bed above thefloor 21, cementitious material is dispensed through a door in thebottom of the hopper onto the floor 21 of the bed 20.

As soon as the hopper 22 reached a position as substantially shown inFIGURE 11, the truss 66 is immersed within the cementitious material 96deposited on the bed 21. The truss 66 is lowered into the cementitiousmaterial 96. An oil film is applied to the positioning bar flanges andthe cut-off bar flanges. The truss 66 is vibrated by means of jackhammers or the like as it is immersed.

As shown in FIGURES 1115, the positioning bar 88 is lowered until itshorizontal flange seats upon the side walls 48 and 50 and the edge ofthe horizontal flange abuts the upstanding flange of the end wall 46.The cutoff bar 92 is lowered until the bottom edge of one of itsvertically extending flanges seats on the side walls 48 and 50 and itsother vertically extending flange seats on the floor 21 of the bed 20.The lateral dimension of the floor 21 is such that the angularlyextending portions of the joist web 72 are seated between the upstandingflanges 98 on the floor 21.

The core pins supported by bar 88 and bar 92 are also dimensioned toseat upon the floor 21 of the casting bed.

Meanwhile, the hopper 22 is continuing its travel along the casting bed20, More cementitious material 96 is deposited upon the floor 21. Assoon as space allows, a second truss 66 is immersed within thecementitious material 96. The positioning bar 88 on the second immersedtruss is seated upon the opposed side walls 48 and 50. An edge of thehorizontal flange of the positioning bar 88 is placed in abutment withthe horizontal flange of the cut-off bar 92 on the previously immersedtruss. This is shown in phantom in FIGURES 14 and 15.

The process is continued as previously described until the casting bed20 is filled and a desired number of trusses 66 have been immersed. Inpractice, the casting bed is approximately feet in length.

The cementitious mixture is then allowed to harden. The hopper 22 isremoved from the tracks 26 and 28. Side walls 48 and 50 are then pivotedaway from the hardened mixture on the floor 21. The end walls 46 and 52are also pivoted away from the hardened mixture.

The individual trusses 66 and cementitious material attached thereto maythen be elevated from the floor 21 of the casting bed 20. A plurality oftruss decks have been formed because of the plurality of chambersdefined by the cut-off bars 92 when they were disposed Within thecementitious material 96. The resultant truss deck is inverted andsupported upon the chords 74. The truss decks may be stacked one on topof each other for ready transportation or storage at the constructionsite.

Each truss deck includes the open web steel joist sections 68 and 70 anda concrete slab reinforced by the joist web 72. Due to the inclusion ofthe upstanding flanges 98 on the floor 21 of the casting bed,longitudinally extending notches 101 are formed along the opposedlongitudinal edges of the slab. As shown in FIGURE 17, the ends of thejoist web 72 are exposed by the notches 101.

The last mentioned construction lends itself to easy assemblage of thetruss decks at the construction site.

As shown in FIGURE 16, the inverted truss decks are adapted to havetheir longitudinal edges placed in abutment to form a roof or floor atthe construction site. The juxtaposed notches 101 form a longitudinalopening 100. The exposed ends of the joist web may be welded together asshown at 102. Hence, each truss deck may be easily joined to another atthe construction site to form a prefabricated floor or roof element.

Removal of the core pins 94 from the hardened mixture results in theformation of a plurality of anchor holes. The prefabricated roof orfloor can then be secured to other structural components of thebuilding.

The present invention may be embodied in other specific forms withoutdeparting from the spirit or essential attributes thereof and,accordingly, reference should be made to the appended claims, ratherthan to the foregoing specification as indicating the scope of theinvention.

I claim:

1. Apparatus for shop-fabricating a reinforced trussdeck comprising acasting bed, said casting bed including a flat stationary floor, movableside Walls on opposite sides of said floor engaging a side edge of thefloor, a movable end wall adjacent one end of said floor between saidside walls, a hopper for dispensing a cementitious mixture, means forselectively causing relative movement between said hopper and said bedto spread a cementitious mixture dispensed by said hopper onto saidfloor, and a plurality of cut-01f bars supported at spaced points alongsaid floor to divide the casting bed into a plurality of chambers, eachbar having a vertical portion generally perpendicular to the floor andextending between the side walls, each bar having a generally horizontalportion extending from the upper edge of the vertical portion so that itmay overlie an end portion of a deck, and means on said horizontalportion adapted to attach same to a horizontal truss.

2. Apparatus in accordance with claim 1 wherein said side walls arepivotally coupled to a support for said floor at a location below theplane of said floor.

3. Apparatus for shop-fabricating a reinforced trussdeck comprising acasting bed, said casting bed including a flat stationary floor, movableside walls on opposite sides of said floor engaging a side edge of thefloor, a movable end wall adjacent one end of said floor between saidside walls, means defining a longitudinally extending protrusion at theintersection of each side wall and said floor, a hopper for dispensing acementitious mixture, means for selectively causing relative movementbetween said hopper and said bed to spread a cementitious mixturedispensed by said hopper onto said floor, and a plurality of cut-01fbars supported at spaced points along said floor to divide the castingbed into a plurality of chambers, each bar having a vertical portiongenerally perpendicular to the floor and extending between the sidewalls, each bar having a generally horizontal portion extending from theupper edge of the vertical portion so that it may overlie an end portionof a deck, and means on said horizontal portion adapted to attach someto a horizontal truss.

4. Apparatus in accordance with claim 3 including rails alongside saidbed, said hopper being supported for movement along said rails.

5. Apparatus in accordance with claim 1 wherein said truss attachingmeans includes apertures adapted to receive core pins.

References Cited UNITED STATES PATENTS 1,175,011 3/1916 Phillipoif249129 1,293,731 2/ 1919 Dowden 249-129 1,326,246 12/1919 Young 294-1191,891,764 12/ 1932 Henderson 121 1,905,897 4/ 1933 Cahill 249-1723,060,540 10/1962 Lapidus 25-2 3,204,316 9/ 1965 Jackson 249--66 FOREIGNPATENTS 1,081,367 5/1960 Germany.

I. SPENCER OVERHOLSER, Primary Examiner. WILLIAM J. STEPHENSON,Examiner. R. D. BALDWIN, Assistant Examiner.

1. APPARATUS FOR SHOP-FABRICATING A REINFORCED TRUSSDECK COMPRISING ACASTING BED, SAID CASTING BED INCLUDING A FLAT STATIONARY FLOOR, MOVABLESIDE WALLS ON OPPOSITE SIDES OF SAID FLOOR ENGAGING A SIDE EDGE OF THEFLOOR, A MOVABLE END WALL ADJACENT ONE END OF SAID FLOOR BETWEEN SAIDSIDE WALLS, A HOPPER FOR DISPENSING A CEMENTITIOUS MIXTURE, MEANS FORSELECTIVELY CAUSING RELATIVE MOVEMENT BETWEEN SAID HOPPER AND SAID BEDTO SPREAD A CEMENTITIOUS MIXTURE DISPENSED BY SAID HOPPER ONTO SAIDFLOOR, AND A PLURALITY OF CUT-OFF BARS SUPPORTED AT SPACED POINTS ALONGSAID FLOOR TO DIVIDE THE CASTING BED INTO A PLURALITY OF CHAMBERS, EACHBAR HAVING A VERTICAL PORTION GENERALLY PERPENDICULAR TO THE FLOOR ANDEXTENDING BETWEEN THE SIDE WALLS, EACH BAR HAVING A GENERALLY HORIZONTALPORTION EXTENDING FROM THE UPPER EDGE OF THE VERTICAL PORTION SO THAT ITMAY OVERLIE AN END PORTION OF A DECK, AND MEANS ON SAID HORIZONTALPORTION ADAPTED TO ATTACH SAME TO A HORIZONTAL TRUSS.